Download BE3450 Operating Instructions BRINKMANN Immersion Pumps

BE3450
Operating Instructions
(Translation of original)
BRINKMANN Immersion Pumps
STA3600…STA4500
Brinkmann Pumpen
K. H. Brinkmann GmbH & Co. KG
Friedrichstraße 2 D-58791 Werdohl
Tel.: +49-2392 / 5006-0
Fax.: +49-2392 / 5006-180
www.brinkmannpumps.de
[email protected]
Subject to change without prior notice.
Order - No.: BE3450 ENGLISH
 Brinkmann Pumpen
Edition 04/2015
Page 1 of 10
Brinkmann Immersions pumps of the series STA3600…STA4500
Contents
1
2
3
4
5
6
7
8
Indication to the manual .................................... 2
Description of product .................................... 2-3
Safety instructions ............................................. 4
Transport and storage ....................................... 4
Installation and connection ................................ 5
Start up / Shut down .......................................... 6
Operation........................................................... 6
Servicing and Maintenance ............................... 6
1 Indication to the manual
This operating manual gives basic instructions
which are to be observed during installation, operation and maintenance of the pump. It is therefore
imperative that this manual be read by the responsible personnel and operator prior to assembly and
commissioning. It is always to be kept available at
the installation site.
1.1
Identification of safety instructions in the
operating manual
Safety instructions given in this manual noncompliance with which would affect safety are
identified by the following symbol
Safety sign according with ISO 3864 – B.3.1
or where electrical safety is involved, with:
Safety sign according with ISO 3864 – B.3.6
Where non-compliance with the safety instructions
may cause a risk to the machine and it’s function
the word
ATTENTION
is inserted.
9
10
11
12
13
Trouble shooter’s guide ..................................... 7
Spare part ...................................................... 8-9
Repair ............................................................... 9
Disposal ............................................................ 9
EC declaration of conformity ........................... 10
2.2 Intended use
The immersion pumps of the series STA are suitable for handling contaminated coolants within the
limiting application in accordance with table 1.
Limit of Application (Table 1)
Type
STA
Mediums
Coolants, cooling- and cutting-oils
Kinetic viscosity
of the medium
...45 mm /s
Temperature of
medium
0 ... 80 °C
Particle-size in
the medium
17 mm
Dry running
Dry running causes increased
wear and should be avoided.
During the test of the direction of
rotation (< 30 s) permissible.
Switching-on
frequency per
hour
Motors 11 kW and higher max. 15
Ambient
temperature
40 °C
Set-up altitude
1000 m
2
2 Description of product
2.1 General description of the pump
Pumps of this type are one-stage rotary pumps
where the impellers are fixed on the driving shaft
extension. The pump shaft and motor shaft are
interconnected by means of a shaft clamp. Pump
and motor form a compact and space-saving unit.
These pumps are fitted out with semi-open impellers.
Vertically mounted pumps are equipped with a
mounting flange. The pump end immerses into the
tank and the motor extends vertically above the
tank.
BE3450
ATTENTION
The pumps are to be operated within their design
limits. Applications outside of these limits are not
approved. The manufacturer is not responsible for
any damages resulting from use of the pumps in
such applications.
Edition 04/2015
Page 2 of 10
2.3
Technical data
1)
Max. del.
pressure bar /
spec. weight 1
Max. del.
volume
l/min
Height
STA3600 / 520
/ 720
/ 920
/1270
4.1
4600
1041
521
721
921
1271
STA4500 / 520
/ 720
/ 920
/1270
5.8
5200
1115
521
721
921
1271
Type
H mm
Depth of
1)
immersion
h mm
Weight
Power
50 / 60 Hz
kW
Noise
2)
level
dBA
331
346
361
426
22.0 / 25.3
82
428
443
458
523
37.0 / 41.5
84
kg
1) Dimensions in accordance with page 5
2) Noise emissions measured in accordance with
DIN 45635 at a distance of 1 m
The motor is surface-cooled and compliant with
DIN IEC 34 and EN 60034 (protection degree IP 55).
BE3450
Edition 04/2015
Page 3 of 10
3 Safety instructions
When operating the pump, the safety instructions
contained in this manual, the relevant national
accident prevention regulations and any other
service and safety instructions issued by the plant
operator are to be observed.
3.1
Hazards in the event of non-compliance
with the safety instructions
Non-compliance with the safety instructions may produce
a risk to the personnel as well as to the environment and
the machine and results in a loss of any right to claim
damages.
For example, non-compliance may involve the following
hazards:
 Failure of important functions of the machines/plant
 Guards for moving parts (e.g. coupling) must not
be removed from the machine while in operation.
 Any leakage of hazardous (e.g. explosive, toxic,
hot) fluids (e.g. from the shaft seal) must be
drained away so as to prevent any risk to persons or the environment. Statutory regulations
are to be complied with.
 Hazards resulting from electricity are to be
prevented (see for example, the VDE Specifications and the bye-laws of the local power supply
utilities).
 The pumps’ stability against falling over is not
ensured unless it is properly mounted onto the
tank.
 Failure of specified procedures of maintenance
and repair
 The female threads on the motor MUST NOT be
used to lift the entire pump and motor assembly.
 Exposure of people to electrical, mechanical and
chemical hazards
3.6
 Endangering the environment due to hazardous
substances being released
3.2
Unauthorized modes of operation
 Pump may not be used in potentially explosive
environments!
 Pump and discharge piping are not designed to
hold any weight and may not be used as a step
ladder.
3.3
Safety instructions relevant for maintenance, inspection and assembly work
Any work on the machine shall only be performed
when it is at a standstill, it being imperative that the
procedure for shutting down the machine described
in this manual be followed.
Pumps and pump units which convey hazardous
media must be decontaminated.
On completion of work all safety and protective
facilities must be re-installed and made operative
again.
Prior to restarting the machine, the instructions
listed under “Start up” are to be observed.
3.7 Signs on the pump
It is imperative that signs affixed to the machine,
e.g.:
Remaining Risk
 arrow indicating the direction of rotation
Risk of Injury!
Risk of squeezing or crushing body parts when
installing or removing the pump exists. Proper and
secured lifting tools must be used.
Risk of burns!
The pump must have cooled down sufficiently prior
to commencing any repair, maintenance or installation.
Qualification and training of operating
personnel
The personnel responsible for operation, maintenance, inspection and assembly must be adequately qualified. Scope of responsibility and supervision
of the personnel must be exactly defined by the
plant operator. If the staff does not have the necessary knowledge, they must be trained and instructed, which may be performed by the machine manufacturer or supplier on behalf of the plant operator.
Moreover, the plant operator is to make sure that
the contents of the operating manual are fully
understood by the personnel.
 symbols indicating fluid connections
be observed and kept legible.
3.8
Unauthorized alterations and production
of spare parts
Any modification may be made to the machine only
after consultation with the manufacturer. Using
spare parts and accessories authorized by the
manufacturer is in the interest of safety. Use of
other parts may exempt the manufacturer from any
liability.
3.4
3.5
4 Transport and storage
Protect the pump against damage when transporting.
The pumps may only be transported in a horizontal
position and hooks or straps must be attached on
the motor and pump end.
Do not use the pump shaft for connecting any
transportation aids such as hooks or straps.
Pumps must be drained prior to their storage.
Store pump in dry and protected areas and protect it
against penetration of foreign bodies.
Always store pump above the freezing point!
Safety instructions relevant for operation
 If hot or cold machine components involve
hazards, they must be guarded against accidental contact.
BE3450
Edition 04/2015
Page 4 of 10
5 Installation and Connection
5.2
5.1 Mechanical installation
During any assembly or disassembly process the
pumps must be secured against tipping trough
ropes for example at all times.
Pumps must be mounted securely. Piping, tank and
pumps must be mounted without any tension.
The inlet is at the bottom of the immersed pump
body. The distance between the inlet and the tank
bottom must be so large that the inlet can not be
blocked by deposits during longer shutdowns.
To obtain the full flow rate it is recommended to
choose for the pipework the nominal bore diameter
of the pumps cross section for connection. Therefore pipe bends should be used, not pipe angles!
The pipework must be qualified for occuring hydraulic pressure.
Electric wiring
All service work must be carried out by qualified service personnel. Pump must be disconnected from the power source and all rotating
parts must stand still. Reassure that pump is
disconnected from power source and cannot be
switched on. Verify that there is no voltage at
the terminal board!
According to the European Standard EN809 a
motor overload must be installed and properly set
to the full load amps stated on the pump name
plate.
It is the responsibility of the machine operator to
decide whether or not an additional emergency
switch must be installed.
5.2.1
Circuit
Tension voltage and frequency must correspond
with the shown specification on the nameplate.
The pump must be wired so that a solid longterm
electrical connection is ensured. Establish a solid
ground connection.
The electrical wiring must be performed according to the wiring diagram shown inside the
terminal box cover. (Please see above sample
wiring diagrams)
(2xM40x1,5)*
Wiring diagram e.g.
Delta connection
3 x 400 V, 50 Hz
resp. 380-420 V, 50 Hz
There may be no foreign objects such as dirt,
particles or humidity inside the terminal board.
Mount terminal board cover to motor tight against
dust and humidity and close up all unused wiring
ports.
*) Dimensions for STA3600
ATTENTION
Maximum tightening torque for piping connections is 200 Nm!
When installed the space around the pump
must be large enough to provide sufficient
cooling of the motor.
Do not prop up the pressure line via the joining
socket.
ATTENTION
When Variable Frequency Drives are used interfering signals might occur.
Non-sinus shaped supply voltage from a variable
frequency drive might result in elevated motor
temperatures.
The pump must be mounted in that way that
rotating parts under the cover of the coolant
tank cannot be touched!
BE3450
Edition 04/2015
Page 5 of 10
6 Start up / Shut down
6.1
Start up
ATTENTION
Switch off at the mains.
After connection the electrical wires, close the
terminal box. Briefly start the motor (max. 30 sec.)
and check the rotation according to the arrow on
the top of the motor.
If the direction is incorrect change over two of the
power leads.
6.2 Shut down
All service work must be carried out by qualified
service personnel. Pump must be disconnected
from the power source and all rotating parts must
stand still. Reassure that pump is disconnected
from power source and cannot be switched on.
Verify that there is no voltage at the terminal board!
Open terminal box and disconnect the power leads.
Empty out the pump.
If the pump should lock up and cease, shut
pump down (see 6.2) and disconnect from
power supply. Pump must be uninstalled and
removed from the system prior to its repair.
8 Servicing and Maintenance
ATTENTION
The surface of the motor must be kept free of dirt.
The motor shaft is spinning in permanently greased
ball bearings (with special grease and increased
bearing play) and does not require any special
maintenance.
7 Operation
Liquid level
According to the drawing shown below, the maximum liquid level must stay about 30 mm below the
mounting flange, also ensure that the minimal liquid
level for the STA pump is 150 mm before starting
up the motor.
max.
liquid level
min.
liquid level
BE3450
Edition 04/2015
Page 6 of 10
9 Trouble shooter’s guide
Fault
Cause
Remedy
Motor does not start, no motor
noise
At least two of the power supply
leads have failed
Check fuses, terminals and supply
leads .
Overload has tripped
Inspect overload
One of the supply leads has failed
See above
Impeller faulty
Motor bearing faulty
Replace impeller
Replace bearing
Overload trips
Pump locked up mechanically
High on/of cycling frequency
Inspect pump hydraulics
Check application
Power consumption is too high
Wrong direction of rotation of
impeller
Lime or other deposits
mechanical friction
See above
High on/off cycling frequency
Wrong power supply (voltage or
cycles)
See above
Power supply must correspond with
name plate rating
Insufficient cooling
Check air flow at motor fan
Pump does not pump
liquid level too low
Pump mechanism faulty
Pipe blocked
Fill up liquid
replace pump mechanism
Clean pipe
Insufficient flow and pressure
Wrong direction of rotation of
impeller
Change over two power supply
leads
Pump mechanism silted up
Worn pump mechanism
Clean pump mechanism
Replace pump mechanism
Incorrect flow or pressure
Wrong power supply (voltage or
cycles)
Power supply must correspond with
name plate rating
Running noise/Vibration
Foreign objects in pump end
Impeller damaged
Bearing/Bushing broken
Remove foreign objects
Replace impeller
Replace bearing/bushing
Motor does not start, humming noise
Motor overheats
BE3450
Edition 04/2015
Clean pump mechanism
repair pump
Page 7 of 10
10 Spare part
10.1 Spare part list for the immersion pumps
of the series STA3600…STA4500
Item Description
1 Motor
2 Bearing housing
3 Woodruff key
4 Bearing shaft
5 Ball bearing
6 Socket head cap screw with lock
7 Ball bearing
8 Bearing cover
9 Coupling
10 Intermediate plate
11 Socket head cap screw with lock
12 Nilos-ring
13 Compensation disk
14 Socket head cap screw
16 Socket head cap screw
17 Nut with flange
19 Spring washer
20 Shaft nut
50 Pump body
51 Spacer
52 Inlet cover
55 Impeller
58 Pump plate
60 O-ring
61 Socket head cap screw with lock
62 Bearing bush
63 Running sleeve
64 Woodruff key
65 Casing ring
66 O-ring
68 Splash ring
70 Socket head cap screw with lock
71 Rotary shaft seal
74 Socket head cap screw with lock
77 Hexagon thin nut
82 Joining socket
83 Socket head cap screw
84 Spring washer
85 O-ring
86 Screw plug
87 Sealing ring
92 Insert shaft
93 Shaft clamp
BE3450
Edition 04/2015
DIN 628
DIN 912
DIN 628
DIN 912
DIN 912
DIN 912
DIN 7980
DIN 912
DIN 6888
DIN 912
DIN 912
DIN 912
DIN 7980
DIN 908
DIN 7603
Page 8 of 10
10.2 Indications to the spare part order
Spare parts are available from the supplier.
Standard commercially available parts are to be
purchased in accordance with the model type.
The ordering of spare parts should contain the
following details:
1. Pumptype
e.g. STA3600/920
2. Pump No.
e.g. 04153450
The date of the construction year is a component of the pumps type number.
3. Voltage, Frequency and Power
Take item 1, 2 and 3 from the nameplate
4. Spare part with item No.
e.g. Inlet cover item No. 52
11 Repair Instructions / Replacing shaft
clamps and shafts
3
1
2
1 = Shaft clamp
2 = Insert / extension shaft
3 = Motor shaft / Insert shaft
11.1 Dismantling the insert shaft or extension
shaft
– Disconnect the submergible pump from the
mains both electrically and mechanically.
– Remove pump from system. Secure pump
against tipping over, i.e. use ropes to secure
pump.
– Disassemble the motor. Set the pump down on
the intermediate plate. Dismantle the pump unit
and the extension pump body (if appropriate).
Wear safety gloves!
Risk of injury due to sharp edges on pump components, i.e. impeller blades.
– Loosen the screws on the shaft clamp (1) one
after the other.
– Loosen the screws on the shaft clamp (1) (see
above), pull the insert shaft (2) off the motor
shaft (3).
11.2 Assembling the insert shaft and motor
shaft
ATTENTION
Clean the contact surfaces of the insert shaft (2)
(inside) and the motor shaft (3). They must not
be lubricated or oiled.
– Set the pump down on the intermediate plate.
– Position the shaft clamp (1) (use a new shaft
clamp) in the centre of the cranked clamping diameter (2) of the insert shaft.
– Insert the motor shaft (3) into the insert shaft (2).
– Tighten:
Mark the first screw and tighten all the screws
evenly by hand, one after the other in a clockwise direction (not cross-ways).
– This must follow until abutting faces of the inner
and outer rings of the screw-head side axially
align. Proper bracing can be verified visually.
– Use a torque screwdriver to tighten each screw
first with 20 Nm then with 30 Nm and finally with
35 Nm (in a clockwise direction again).
– Mount the pump body.
The remainder of the reassembly process is to be
completed in the opposite order of the prior described dismantling process.
ATTENTION
Note torques for the screw connections!
When putting the pump back into use, make sure
the direction of rotation is correct!
Tightening torques for screwed connections
Thread - 
Strength
classes
Tightening
torque (Nm)
M5
8.8
M12
8.8
M16
8.8
M20
5 Nm
80 Nm
190 Nm
390 Nm
12 Disposal
Do not, under any circumstances, remove the
screws completely, danger of injury!
– Remove the outer race over the jacking-screws
and tensioning screws, inner ring from outer
ring. The squeezing off is finished when the outer ring has been completely removed.
– Remove the extension shaft (2) and shaft clamp
(1).
– Dismantle the pump body.
BE3450
When disposing of the pump or the packaging
materials the local and national regulation for
proper disposal must be complied with.
Prior to its disposal, the pump must be completely
drained and decontaminated if necessary.
Edition 04/2015
Page 9 of 10
13 EC declaration of conformity
DEUTSCH / ENGLISH /FRANÇAIS / ESPAÑOL
EG-Konformitätserklärung
EC declaration of conformity / Déclaration de conformité CE / Declaración de conformidad CE
Hersteller / Manufacturer / Constructeur / Fabricante
Brinkmann Pumpen, K. H. Brinkmann GmbH & Co. KG
Friedrichstraße 2, D-58791 Werdohl
Produktbezeichnung / Product name / Désignation du produit / Designación del producto
Tauchpumpen / Immersion pumps / Pompes plongeantes / Bombas de inmersión
Typ / Type / Tipo
STA3600…STA4500
Das bezeichnete Produkt stimmt mit den folgenden Richtlinien des Rates zur Angleichung der Rechtsvorschriften der
EG-Mitgliedsstaaten überein:
The named product conforms to the following Council Directives on approximation of laws of the EEC Member States:
Le produit sus-mentionné est conforme aux Directives du Conseil concernant le rapprochement des législations des
Etats membres CEE:
El producto designado cumple con las Directivas del Consejo relativas a la aproximación de las legislaciones de los
Estados Miembros de la CEE:
2006/42/EG
2006/42/EC
2006/42/CEE
2006/42/CEE
Richtlinie für Maschinen
Council Directive for machinery
Directive du Conseil pour les machines
Directivas del Consejo para máquinas
2004/108/EG
2004/108/EC
2004/108/CEE
2004/108/CEE
Richtlinie für elektromagnetische Verträglichkeit
Council Directive for Electromagnetic compatibility
Directive du Conseil pour Compatibilité électromagnétique
Directivas del Consejo para Compatibilidad electromagnética
Hinsichtlich der elektrischen Gefahren wurden gemäß Anhang I Nr. 1.5.1 der Maschinenrichtlinie 2006/42/EG die Schutzziele der Niederspannungsrichtlinie 2006/95/EG eingehalten.
With respect to potential electrical hazards as stated in appendix І No. 1.5.1 of the machine guide lines 2006/42/EG all
safety protection goals are met according to the low voltage guide lines 2006/95/EG.
Conformément à l'annexe I N° 1.5.1 de la Directive "Machines" (2006/42/CE) les objectifs de sécurité relatifs au
matériel électrique de la Directive "Basse Tension" ont été respectés.
Con respecto al potencial peligro eléctrico como se indica en el apéndice I No. 1.5.1 del manual de la máquina
2006/42/EG, todos los medios de protección de seguridad se encuentran según la guía de bajo voltaje 2006/95/EG.
Die Übereinstimmung mit den Vorschriften dieser Richtlinien wird nachgewiesen durch die vollständige Einhaltung folgender Normen:
Conformity with the requirements of this Directives is testified by complete adherence to the following standards:
La conformité aux prescriptions de ces Directives est démontrée par la conformité intégrale avec les normes suivantes:
La conformidad con las prescripciones de estas directivas queda justificada por haber cumplido totalmente las siguientes
normas:
Harmonisierte Europ. Normen / Harmonised Europ. Standards / Normes europ. harmonisées / Normas europ. armonizadas
EN 809 :1998+A1 :2009+AC :2010
EN ISO 12100 :2010
EN 60204-1 :2006/AC :2010 EN 61000-32 :2006/A2 :2009
EN 61000-3-3 :2013
EN 61000-6-2 :2005/AC :2005 EN 61000-6-3 :2007/A1 :2011/AC :2012
Nationale Normen / National Standards / Normes nationales / Normas nacionales : EN 60034-1 :2010/AC :2010
Die Hinweise in der Betriebsanleitung für den Einbau und die Inbetriebnahme der Pumpe sind zu beachten.
The instructions contained in the operating manual for installation and start up the pump have to be followed.
Les indications d’installation / montage et de mise en service de la pompe prévues dans l’instruction d’emploi
doivent être suivies.
Tenga en cuenta las instrucciones en el manual para la instalación y puesta en marcha de la bomba.
Brinkmann Pumpen, K. H. Brinkmann GmbH & Co. KG
Werdohl, 16.04.2015
...............................................................................................
Norbert Burkl Leiter Qualitätsmanagement / Manager of quality
management / Directeur de gestion de la qualité /
Director de gestión de calidad
BE3450
Edition 04/2015
Dr. H. Abou Dayé
K. H. Brinkmann GmbH & Co. KG
Friedrichstraße 2, D-58791 Werdohl
Dokumentationsbevollmächtigter / Representative of
documentation/ Mandataire de documentation / Mandatario
de documentación
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